API RP 74 1st Ed. Oct. 2001 (R2007) - Recommended Practice for Occupational Safety for Onshore Oil and Gas Production Operation

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Recommended Practice for Occupational Safety for Onshore Oil and Gas Production Operation

API RECOMMENDED PRACTICE 74 FIRST EDITION, OCTOBER 2001 REAFFIRMED, MARCH 2007

Recommended Practice for Occupational Safety for Onshore Oil and Gas Production Operations

Upstream Segment RECOMMENDED PRACTICE 74 FIRST EDITION, OCTOBER 2001

SPECIAL NOTES API publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed. API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations under local, state, or federal laws. Information concerning safety and health risks and proper precautions with respect to particular materials and conditions should be obtained from the employer, the manufacturer or supplier of that material, or the material safety data sheet. Nothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent. Generally, API standards are reviewed and revised, reafÞrmed, or withdrawn at least every Þve years. Sometimes a one-time extension of up to two years will be added to this review cycle. This publication will no longer be in effect Þve years after its publication date as an operative API standard or, where an extension has been granted, upon republication. Status of the publication can be ascertained from the API Upstream Segment [telephone (202) 6828000]. A catalog of API publications and materials is published annually and updated quarterly by API, 1220 L Street, N.W., Washington, D.C. 20005. This document was produced under API standardization procedures that ensure appropriate notiÞcation and participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this standard or comments and questions concerning the procedures under which this standard was developed should be directed in writing to the general manager of the Upstream Segment, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005. Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the general manager. API standards are published to facilitate the broad availability of proven, sound engineering and operating practices. These standards are not intended to obviate the need for applying sound engineering judgment regarding when and where these standards should be utilized. The formulation and publication of API standards is not intended in any way to inhibit anyone from using any other practices. Any manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to the applicable API standard.

All rights reserved. No part of this work may be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220 L Street, N.W., Washington, D.C. 20005. Copyright © 2001 American Petroleum Institute

FOREWORD This recommended practice was prepared by the API Production Safety Subcommittee. This publication is under the jurisdiction of the American Petroleum Institute Upstream DepartmentÕs Executive Committee on Drilling and Production Operations. The goal of this recommended practice is to assist the oil and gas industry in promoting personnel and public safety. This publication has intentionally stressed recommended safe operating practices concentrating on personnel and public safety. THE PUBLICATION DOES NOT, HOWEVER, PURPORT TO BE SO COMPREHENSIVE AS TO PRESENT ALL OF THE RECOMMENDED SAFE OPERATING PRACTICES THAT CAN AFFECT SAFETY IN ONSHORE OIL AND GAS PRODUCTION OPERATIONS. It is intended that this voluntary recommended practice will promote and maintain safe working conditions for personnel engaged in onshore production operations. Every effort has been made by API to assure the accuracy and reliability of data contained in this document. However, the Institute makes no representation, warranty, or guarantee in connection with the publication of this recommended practice and hereby expressly disclaims any liability or responsibility for loss or application hereunder or for any violation of local, state, or federal laws with which the contents may conßict. INFORMATION CONCERNING SAFETY AND HEALTH RISKS AND PROPER PRECAUTIONS WITH RESPECT TO PARTICULAR MATERIALS AND CONDITIONS SHOULD BE OBTAINED FROM THE EMPLOYER, THE MANUFACTURER OR SUPPLIER OF THAT MATERIAL, OR THE MATERIAL SAFETY DATA SHEET (MSDS). Users of this publication are reminded that constantly developing technology and specialized or limited operations do not permit complete coverage of all operations or alternatives. Recommendations presented herein are not intended to inhibit developing technology and equipment improvements or improved operational procedures. This document is not a substitute for qualiÞed engineering analysis and judgment to Þt the speciÞc operations situation. The publication is available for review by federal and state agencies or authorities and possible use as a model safe practice to assist in preparation or revision of occupational safety codes or regulations. Recommendations set forth in this publication are viewed as one satisfactory method for accomplishing a desired result. They should not be considered as the only method for achieving the desired results. This publication includes usage of the verbs ÒshallÓ and Òshould,Ó whichever is deemed most applicable for the speciÞc situation. For the purposes of this publication, the following deÞnitions are applicable: Shall: Denotes that the recommended practice has universal application to that speciÞc activity. Should: Denotes a recommended practice: (1) where a safe comparable alternative practice is available; (2) that may be impractical under certain circumstances; or (3) that may be unnecessary for personnel safety under certain circumstances. Proposed changes in these interpretations and usages should be brought to the attention of the responsible authorizing committee to determine that the intent of the publication will be sustained. API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any federal, state, or municipal regulation with which this publication may conßict. Suggested revisions are invited and should be submitted to the general manager of the Upstream Segment, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005.

iii

CONTENTS Page

1

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2.1 ReferencesÑIndustry Codes, Practices, and Standards . . . . . . . . . . . . . . . . . . . . 1

3

DEFINITIONS AND ACRONYMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4

SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Hazard Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Personal Protective Equipment (PPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 Fall Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 Machinery and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 Welding and Cutting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

CONTRACTOR SAFETY AND TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6

SAFE WORK PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6.1 Load Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6.2 ConÞned Space, Excavations, and Hazardous Environments . . . . . . . . . . . . . . . . 8 6.3 Lockout/Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6.4 Hotwork, Welding, and Flame Cutting Operations . . . . . . . . . . . . . . . . . . . . . . . . 9 6.5 Work in Proximity to Exposed Energized Power Sources . . . . . . . . . . . . . . . . . 10

7

DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Emergency Eye or Body Wash Stations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Critical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Changes to Critical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4 Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Fire Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 Grounding and Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 Flammable Liquids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

9

PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 9.1 Well Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

10 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Tank Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 Drilling and Well Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iv

1 1 1 1

4 4 4 5 6 6 6 7

11 11 11 11 11 11 12 12 13

15 15 15 15

Page

11 INCIDENT INVESTIGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 12 EMERGENCY RESPONSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2 Medical Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3 First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 15 15 15

13 SPECIAL OPERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 Well Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2 Pumping and Hot Oil Operations (Flowlines) . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3 Pigging Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4 Hot Tapping on Equipment in Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 15 15 16 16

APPENDIX A APPENDIX B

EXAMPLE LEASE PRODUCTION SAFETY CHECKLIST . . . . . . . 17 EXAMPLE COMPRESSOR/BOOSTER STATIONS SAFETY CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Tables 1 Maximum Permissible Noise Exposures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2 Recommended Minimum Clearances Between Power Lines and Derricks, Masts, or Guylines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

v

Recommended Practice for Occupational Safety for Onshore Oil and Gas Production Operations 1 General

RP12N

1.1 PURPOSE

RP 12R1

The purpose of this document is to recommend practices and procedures for promotion and maintenance of safe working conditions for personnel engaged in onshore oil and gas production, including special services.

RP49

1.2 SCOPE

RP 55

These recommendations apply to production operations as deÞned herein. For information on drilling, well servicing and workover operations, see API RP 54.

RP 75

RP 54

1.3 RESPONSIBILITY RP 500

These recommendations are made recognizing that owners, operators, contractors, and their personnel have separate responsibilities that may be contractual in nature. To ensure the safe performance of work covered by these recommendations, each employer should provide training and instruction for its personnel. It is not the intent of these recommendations to alter the contractual relationship(s) between the parties. The well owner or operator should provide and the contractor should seek pertinent information that is known or assumed and that the contractor may need to assure a safe operation. At all times, the speciÞc work activity being performed should be under the immediate supervision of an authorized person who has the authority to commence, modify, or cease the work methods or operations, as necessary, to ensure the safety of affected personnel and the general public. The authorized person should observe changing conditions and improve, whenever required, the work methods to promote increased protection for the personnel.

RP505

Publ 510

Publ 520 Publ 521 RP 750 RP 752

Publ 761

2 References

Std 1104 RP 1107 RP 2003

2.1 REFERENCES—INDUSTRY CODES, PRACTICES, AND STANDARDS The following publications are either referenced in this recommended practice or would be useful in its implementation:

Publ 2009

American Petroleum Institute Spec 6A Wellhead and Christmas Tree Equipment Spec 11E Pumping Units RP 11ER Guarding of Pumping Units (ANSI) Spec 12J Oil and Gas Separators Spec 12K Indirect-Type Oil Field Heaters Spec 12L Vertical and Horizontal Emulsion Heaters

Std 2015 Publ 2201 Publ 2207 Publ 2217A 1

Operations, Maintenance and Testing of Firebox Flame Arrestors Setting, Maintenance, Inspection, Operation, and Repair of Tanks in Production Service Drilling and Well Servicing Operations Involving Hydrogen SulÞde Occupational Safety for Oil and Gas Well Drilling and Servicing Operations Oil and Gas Production and Gas Processing Plant Operations Involving Hydrogen SulÞde Recommended Practice for Development of a Safety and Environmental Management Program for Outer Continental Shelf (OCS) Operations and Facilities ClassiÞcation of Locations for Electrical Installations at Petroleum Facilities ClassiÞed as Class I, Division 1 and Division 2 ClassiÞcation of Locations for Electrical Installations at Petroleum Facilities ClassiÞed as Class I, Zone 0, Zone 1 and Zone 2 Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair, and Alteration Sizing, Selection, and Installation of Pressure-Relieving Devices in ReÞneries Guide for Pressure-Relieving and Depressuring Systems Management of Process Hazards Management of Hazards Associated with Location of Process Plant Buildings, CMA Managers Guide Model Risk Management Program Guidance for E&P FacilitiesÑGuidance for Complying with EPAÕs Rule (40 CFR 68) Welding of Pipelines and Related Facilities Pipeline Maintenance Welding Practices Protection Against Ignitions Arising Out of Static, Lightning, and Stray Currents Safe Welding and Cutting Practices in ReÞneries, Gasoline Plants, and Petrochemical Plants Safe Entry and Cleaning Petroleum Storage Tanks Procedures for Welding or Hot Tapping on Equipment in Service Preparing Tank Bottoms for Hot Work Guidelines for Work in Inert ConÞned Spaces in the Petroleum Industry

2

API RECOMMENDED PRACTICE 74

RP 2220 RP 2221 Publ 2510 Publ 2510A

Publ 9100

Improving Owner and Contractor Safety Performance Managers Guide to Implementing a Contractor Safety Program Design and Construction of LiqueÞed Petroleum Gas (LPG) Installations Fire-Protection Considerations for the Design and Operation of LiqueÞed Petroleum Gas (LPG) Storage Facilities Model Environmental Health and Safety Management System and Guidance Document

ACGIH1 Threshold Limit Values and Biological Indices Industrial Ventilation, A Manual of Recommended Practice, 22nd Edition ANSI2 B15.1 S1.13-1995 S12.6-1997 S12.19-1996 S12.36 Z41.1-1979 Z87.1 Z87.2 Z88.2-1992 Z89.1 Z117.1-1995 Z358.1 Z359.1

2117.1 ANSI/IES3 RP7-1988

Safety Standard for Mechanical Power Transmission Apparatus Measurement of Sound Pressure Levels in Air Methods for Measuring the Real-Ear Attenuation of Hearing Protectors Measurement of Occupational Noise Exposure Survey Methods for the Determination of Sound Power Levels of Noise Sources MenÕs Safety-Toe Footwear Standard Practice for Occupational and Educational Eye and Face Protection Safety Requirements for Industrial Protective Helmets for Electrical Workers, Class B Respiratory Protection Safety Requirements for Industrial Head Protection Safety Requirements for ConÞned Space Emergency Eyewash and Shower Equipment Safety Requirements for Personal Fall Arrest Systems, Subsystems and Components ConÞned Space Industrial Lighting

1American Conference of Governmental Industrial Hygienists, 1330 Kemper Meadow Drive, Suite 600, Cincinnati, Ohio 45240-1634. 2American National Standards Institute, 11 West 42nd Street, New York, New York 10036. 3Illuminating Engineering Society of North America, 120 Wall Street, New York, New York 10005-4001.

ASME4 ASME Boiler and Pressure Vessel Code, Sections VIII and IX ASNT5 Recommended Practice No. ASNT-TC-1A NACE6 Std MR0175

NFPA7 NFPA 10 NFPA 30 NFPA 51B NFPA 58 NFPA 70 NFPA 77

Requirements for SulÞde Stress Cracking Resistant Metallic Material for Oil Field Equipment Standard for Portable Fire Extinguishers Flammable and Combustible Liquids Code Standard for Fire Prevention in Use of Cutting and Welding Processes Standard for the Storage and Handling of LiqueÞed Petroleum Gases National Electrical Code Recommended Practice on Static Electricity

OSHA8 29 CFR 1910 29 CFR 1926

3 Definitions and Acronyms The following deÞnitions and abbreviations are provided to help clarify and explain use of certain terms in this publication. Users should recognize that some of these terms could be used in other instances where the application or meaning may vary from the speciÞc information provided herein. 3.1 adequate ventilation: Adequate ventilation is for the prevention of Þre and explosions. Adequate ventilation is ventilation (natural or artiÞcial) that is sufÞcient to prevent the accumulation of signiÞcant quantities of vapor-air mixtures in concentrations above 10% of their lower explosive limit (LEL). 3.2 ANSI: American National Standards Institute. 3.3 API: American Petroleum Institute. 3.4 approved: Sanctioned, endorsed, accredited, certiÞed, or accepted by a duly constituted and recognized authority or agency. 4ASME International, 3 Park Avenue, New York, New York 100165990. 5American Society of Nondestructive Testing, 1711 Arlington Lane, Columbus, Ohio 43228. 6NACE International, 1440 South Creek Drive, P.O. Box 218340, Houston, Texas 77218-8340. 7National Fire Protection Association, 1 Batterymarch Park, P.O. Box 9101, Quincy, Massachusetts 02269-9101. 8Occupational Safety and Health Administration, U.S. Department of Labor, Washington, D.C. 20402.

RECOMMENDED PRACTICE FOR OCCUPATIONAL SAFETY FOR ONSHORE OIL AND GAS PRODUCTION OPERATIONS

3.5 ASTM: American Society for Testing and Materials. 3.6 authorized person: A qualiÞed person assigned by an employer to perform or supervise the performance of a speciÞc type of duty or duties at the work site. 3.7 cellar: Excavation around the wellhead to provide space for items of equipment at the top of the wellbore.

3

3.20 lanyard: A ßexible line of rope, wire rope, or strap which generally has a connector at each end for connecting the body belt or body harness to a deceleration device, lifeline or anchorage. 3.21 lockout/tagout: A procedure to control hazardous energy. 3.22 NFPA: National Fire Protection Association.

3.8 Christmas tree: The valves and Þttings assembled at the top of a completed well to control the ßow of hydrocarbons and other ßuids. See API Spec 6A. 3.9 combustible liquid: Any liquid having a ßash-point at or above 100¡F. 3.10 contractor: Any person or company that contracts or subcontracts to perform all or any part of oil and gas well production operations. 3.11 critical equipment: Equipment and other systems determined to be essential in preventing the occurrence of, or mitigating the consequences of an uncontrolled event. 3.12 electrical classification of areas: Locations are classiÞed according to API RP 500 or API RP 505. 3.13 flammable liquid: Any liquid having a ßashpoint below 100¡F. 3.14 full body harness: Straps which may be secured about a person in a manner that will distribute the fall arrest forces over at least the thighs, pelvis, waist, chest, and shoulders, with means for attaching it to other components of a personal fall arrest system. 3.15 guarded: Covered, shielded, fenced, enclosed, or otherwise protected by means of suitable covers or casings, barrier rails, or screens to eliminate the possibility of accidental contact with or dangerous approach by persons, animals, or objects. 3.16 hazardous substance: Any substance that, by reason of being explosive, ßammable, toxic, corrosive, oxidizing, irritating, or otherwise harmful, has the potential to cause injury, illness, or death. 3.17 hot oil treatment: The process of heating oil and pumping it into piping, tubing, casing, or a formation to remove parafÞn. 3.18 hot tapping (pipe tapping): The process of drilling a hole through the wall of pipe that is under pressure. A special saddle is used to attach a valve and lubricator to the pipe. 3.19 hot work: Work involving electric or gas welding, cutting, brazing, grinding or similar ßame or spark producing operations.

3.23 operator: Lease owner or his designated agent who is responsible for the overall operation of the lease. 3.24 personal fall arrest system (PFAS): A system designed to provide protection to a person from falls. The PFAS should consist of an anchorage, connector and a synthetic webbing full body harness which may include a lanyard and a deceleration device. 3.25 PPE: Personal Protective Equipment. 3.26 pumping unit: Surface equipment used for the purpose of mechanically lifting ßuids from a well. See API Spec 11E and API/ANSI 11ER. 3.27 qualified person: A person who, by possession of a recognized degree, certiÞcate, or professional standing, or who by knowledge, training, or experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter or the work. 3.28 rated working pressure: The maximum internal pressure that equipment is designed to contain and/or control. Working pressure is not to be confused with test pressure. 3.29 shall: For the purpose of this document, shall indicates that the recommended practice(s) has universal application to that speciÞc activity. 3.30 should: For the purpose of this document, should denotes a recommended practice(s) (a) where a safe comparable alternative practice(s) is available; (b) that may be impractical under certain circumstances; or (c) that may be unnecessary for personnel safety under certain circumstances. 3.31 simultaneous operations: Two or more of the following activities being performed in close proximity: production, drilling, completion, workover, wireline (except routine operations), major construction operations, well testing and maintenance. 3.32 supervisor: Person who has been given the control, direction, or supervision of work performed by one or more personnel. 3.33 well servicing: Well work involving pulling or running tubulars or sucker rods, to include but not limited to redrilling, completing, recompleting, workover, and abandoning operations.

4

API RECOMMENDED PRACTICE 74

4 Safety 4.1 SAFETY PRACTICES 4.1.1 Personnel shall be properly trained in relation to their job duties. Additionally, pre-job safety meetings that include all affected personnel, including contractors, should be held to review responsibilities for the operation(s) to be performed. 4.1.2 Personnel should receive instruction in correct work methods to reduce chance of injury to themselves or fellow personnel. 4.1.3 A safety program should be established and maintained. The following elements should be considered when developing a comprehensive safety program: conÞned space entry contractor safety electrical safety emergency response Þre prevention and protection Þrst aid general safety rules hazard communication hazardous environment hot working/welding housekeeping hydrogen sulÞde and sulfur dioxide lifting lockout/tagout other equipment safety (hoists, cranes, etc) periodic reviews personal protective equipment personnel training production equipment safety roles and responsibilities safe use of hand tools safety meetings transportation trenching and excavation Note: Appendix A and Appendix B are examples of safety checklists that may be used to periodically access lease production and compressor/booster stations.

4.1.4 Unsafe and potentially dangerous conditions should be eliminated immediately, if possible, or reported to the supervisor in charge for corrective action. 4.1.5 The offgoing supervisor shall inform the incoming supervisor of any known special hazards or work in progress that may affect the safety of the crew. Incoming personnel shall be alerted to work in progress that could affect their safety. 4.2 HAZARD COMMUNICATION A Hazard Communication Program that evaluates the presence and potential hazards of chemicals found in the work-

place shall be established for onshore oil and gas production operations. Workers shall be provided with information concerning the hazard of chemicals and appropriate measures to protect themselves while working with hazardous chemicals. The program shall be written and include information about hazard evaluation, labeling, material safety data sheets, employee training and methods to review and update changes in the program based on chemical usage. Elements of a program include: a. Hazard EvaluationÑAn inventory of all the hazardous chemicals in the work area shall be completed. An evaluation of the potential hazard of a chemical should be conducted before the hazardous chemical is handled. Generally applicable measures including engineering controls, safe work practices and PPE should be considered for safe handling and use of a hazardous chemical. This information shall be communicated to the worker. b. LabelingÑa labeling system shall be developed that warns of the potential hazards of working with a hazardous chemical. Hazardous chemicals shall identify (at minimum) the material or substance and the physical and health hazards. c. Material Safety Data Sheet (MSDS)ÑChemical manufacturers are normally responsible for developing MSDSs. A MSDS shall be available and readily accessible for each hazardous chemical used in the workplace. A system to collect, maintain, and inform workers about the chemical hazard information found on a MSDS shall be part of the program. d. TrainingÑPersonnel should be provided hazard communication training upon: 1. Initial assignment to a work area. 2. When a new chemical has been introduced. 3. A new physical or health hazard has been identiÞed or a process change has occurred that involves a hazardous chemical. At minimum the training should include: 1. Information regarding the method and observations that can be used to detect the presence of a release of a hazardous chemical in the work area. 2. Physical and health hazard information. 3. Measures to protect the worker from harmful exposure, including, engineering, safe work practices, emergency procedures, PPE use, etc. 4. SpeciÞc details on how to recognize and understand labels in the work area, MSDS interpretation, and safe procedures when working with hazardous chemicals. e. Non-Routine TaskÑspecial considerations should be developed to handle non-routine work (e.g., upset or emergency conditions, cleaning out vessels). f. ContractorsÑHazard communication information shall be shared with contractors and their employees. Refer to API RP 2221.

RECOMMENDED PRACTICE FOR OCCUPATIONAL SAFETY FOR ONSHORE OIL AND GAS PRODUCTION OPERATIONS

4.3 PERSONAL PROTECTIVE EQUIPMENT (PPE) 4.3.1 General Employers should assess their work sites to evaluate the types of hazards present at their onshore oil and gas production operations. When it is impractical to reduce a hazard to acceptable levels by administrative or engineering controls, personal protective equipment appropriate for the hazard shall be selected for use. Personal protective equipment for hearing, eyes, face, head, extremities, protective clothing, respiratory protection and fall protection shall be considered for use to protect personnel. 4.3.2 Wearing Apparel 4.3.2.1 When identiÞed as part of the employerÕs PPE assessment, a safety hard hat shall be worn by each person in the work area. The safety hard hat shall meet the requirements of ANSI Z89.1 Safety Requirements for Industrial Head Protection; or ANSI Z89.2 Safety Requirements for Industrial Protective Helmets for Electrical Workers, Class B. 4.3.2.2 Eye protection equipment appropriate for the work being done shall be worn by personnel where there is a reasonable probability of injury to the eyes from ßying objects, chemicals, or injurious light or heat that can be prevented by such equipment. This protective equipment shall meet the requirements of ANSI Z87.1 Practice for Occupational and Educational Eye and Face Protection. 4.3.2.3 When identiÞed as part of the employerÕs PPE assessment, safety shoes, safety boots, or toe guards shall be worn. Safety-toe footwear shall meet the requirements of ANSI Z41.1 MenÕs Safety-Toe Footwear. 4.3.2.4 The employerÕs PPE assessment should include possible chemical exposures that may necessitate the use of gloves, aprons, boots, or other protective equipment, as appropriate. The assessment should also evaluate the need for gloves or other protective clothing to provide protection from temperature extremes or sharp objects. 4.3.2.5 Appropriate clothing should be worn at all times. Loose or poorly Þtted clothing should not be worn. 4.3.2.6 Personnel should not work in clothing that is saturated with any ßammable, hazardous, or irritating substance(s). Such clothing should be immediately removed and replaced with suitable clothing after the affected skin area has been thoroughly washed and, if necessary, treated. 4.3.2.7 Personnel should not wear jewelry or other adornments subject to snagging or hanging and causing injury while in the work area. 4.3.2.8 Personnel with hair of such length as to be a hazard in work areas should keep it contained in a suitable manner while performing their duties. Hair and beard styles shall not

5

interfere with the effective functioning of head, eye, face, or respiratory protective equipment, if such equipment is required at the work site. 4.3.2.9 Personnel working over or near water where a danger of drowning exists shall be provided with approved personal ßotation devices in serviceable condition. 4.3.3 Hearing Protection 4.3.3.1 Protection against the effects of noise exposure shall be provided when the sound levels exceed those shown in Table 1. For guidance on measuring sound levels, see ANSI S12.19-1996 Measurement of Occupational Noise Exposure; ANSI S1.13-1995 Measurement of Sound Pressure Levels in Air; and ANSI S12.36-R1997. 4.3.3.2 When personnel are subjected to sound levels exceeding those listed in Table 1, feasible administrative or engineering controls should be utilized. If such controls fail to reduce sound levels within the levels of Table 1, personal protective equipment shall be provided and used to reduce sound levels within the levels of the table. For guidance on hearing protection equipment, see ANSI S12.6-1997 Methods for Measuring the Real-Ear Attenuation of Hearing Protectors. 4.3.3.3 Employers should consider implementing the elements of a hearing conservation program as appropriate to protect the hearing of personnel. Table 1—Maximum Permissible Noise Exposuresa Duration per day, hours 12 8 6 4 3 2 11/2 1 1/2 1/4 or less

Sound levelb dBA slow response 85 90 92 95 97 100 102 105 110 115

Notes: a When the daily noise exposure is composed of two or more periods of noise exposure of different levels, their combined effect shall be considered rather than the individual effect of each. Exposure to impulsive or impact noise should not exceed 140 dBA peak sound pressure level. b Measured on the A scale of a standard sound level meter at slow response.

4.3.4 Respiratory Protection 4.3.4.1 An assessment of the work area shall be done to identify the potential hazards that may require respiratory

6

API RECOMMENDED PRACTICE 74

protection. Employees shall wear respiratory protection appropriate for potential workplace atmospheric hazards. 4.3.4.2 For respiratory protection practices, including equipment selection, use, medical surveillance, Þt testing, storage, inspection, maintenance, and training, see ANSI Z88.2-1992, Respiratory Protection. 4.3.4.3 Tight-Þtting air purifying respirators shall be used only in areas where sufÞcient oxygen exists. 4.3.4.4 Approved self-contained or supplied-air breathing equipment shall be used for those atmospheres where tests indicate toxic or hazardous gases are present in quantities immediately dangerous to life or health (IDLH) or oxygen content is less than necessary to sustain life. Air from the utility system shall not be used as the source for breathing air supply. 4.3.4.5 Cartridge type respirators shall not be used for protection from hydrogen sulÞde or sulfur dioxide. 4.3.4.6 Personnel who may be expected to use breathing equipment shall be trained in the use and operation of breathing equipment available at the work site. Personnel shall be advised of the potential dangers of ßammable, hazardous, and insufÞcient oxygen atmosphere. See API RP 55, Conducting Oil and Gas Producing and Gas Processing Plant Operations Involving Hydrogen SulÞdes. 4.4 FALL PROTECTION 4.4.1 All personnel, when engaged in work 6 ft or higher above the ground or adjacent working surfaces, shall be protected at all times from falling by guardrail systems, safety net systems, or personal fall arrest systems (PFAS). When the employer can demonstrate that it is unfeasible or creates a greater hazard to use these systems, the employer shall develop and implement an alternative fall protection plan that provides for personnel safety. When PFAS are used, the following shall apply: a. Personnel shall use a full body harness manufactured in accordance with ANSI Z359.1. b. PFAS shall be inspected prior to each use. c. The full body harness shall be attached by means of a lanyard with double-locking snap-hooks to an anchor or structural member capable of supporting a minimum dead weight of 5,400 pounds. d. A separate lanyard shall be used by each person requiring a lanyard. The lanyard shall be adjusted to permit a maximum drop of 5 ft in case of a fall. e. ManufacturerÕs instructions for inspection and replacement of PFAS should be followed.

4.5 HOUSEKEEPING 4.5.1 Work areas should be maintained clean and free of debris and tripping hazards. 4.5.2 Leaks or spills should be promptly cleaned up to eliminate personnel slipping and Þre hazards. 4.5.3 If personnel are required to work in a cellar, it should be kept reasonably clear of water or oil accumulation. No loose equipment or materials should be in the cellar except those in use or about to be used. 4.5.4 Care should be taken to leave egress routes open. 4.5.5 Tools and equipment should be securely placed and stored in a position or manner so they will not fall. 4.5.6 Clear access to control devices, emergency shutdown, emergency equipment, etc, shall be maintained. 4.6 MACHINERY AND TOOLS 4.6.1 Personnel shall only operate machinery that they are qualiÞed to operate. 4.6.2 All belts, drive chains, gears, and drives shall have guards installed to prevent personnel from coming in contact with moving parts. See ANSI B15.1, Safety Standard for Mechanical Power Transmission Apparatus, and API/ANSI 11ER for construction speciÞcations and clearances for such equipment guards. 4.6.3 Machinery shall not be operated unless all guards are in position and are in properly maintained condition. During maintenance or repair work limited testing may be performed by qualiÞed personnel without guards in place. 4.6.4 Maintenance personnel should report to the supervisor prior to beginning repairs. They should report hazards that may be introduced. They should report when repairs are completed. 4.6.5 Personnel shall not clean, lubricate, or repair any machinery where there is a hazard of contact with moving parts until such machinery has been stopped or such parts have been properly guarded. See Lockout/Tagout. 4.6.6 Hand power tools and similar equipment shall be maintained in a safe condition. 4.6.7 Electric hand tools shall be double insulated or grounded as speciÞed in NFPA 70. Ground fault circuit interruption protection shall be used in damp locations. 4.6.8 Electric or pneumatic hand tools shall have a deadman switch or be arranged so that the starting switch cannot be locked in.

RECOMMENDED PRACTICE FOR OCCUPATIONAL SAFETY FOR ONSHORE OIL AND GAS PRODUCTION OPERATIONS

4.6.9 When personnel are climbing ladders, any tools or other such materials they are carrying should be secured rather than hand held. 4.7 WELDING AND CUTTING EQUIPMENT 4.7.1 Apparatus such as torches, regulators, hoses and arc welding machines shall be in good operating condition and repair. Only approved oxygen and acetylene cylinders shall be used. 4.7.2 Oxygen and acetylene torches shall be equipped with ßash-back arrestors. 4.7.3 All cylinders shall be equipped with a valve protection cap, a collar, or recess to protect the valve. Valve caps should be in place except when cylinders are connected for use. 4.7.4 Cylinders should be stored in assigned places and shall be secured to prevent accidental overturning. 4.7.5 Cylinders should not be kept in unventilated enclosures, such as lockers and cupboards. 4.7.6 Oxygen cylinders in storage shall be separated from fuel gas cylinders or combustible materials a minimum distance of 20 ft (6.1 m) or by a noncombustible barrier at least 5 ft (1.5 m) high. 4.7.7 Acetylene cylinders shall be stored valve end up with protective caps afÞxed and properly secured. When a job using acetylene devices is completed or prior to transporting acetylene cylinders, the valve on the acetylene cylinder shall be closed and pressure on the hoses bled to zero. 4.7.8 When transporting cylinders by a crane or derrick, a cradle, bin, or other suitable platform should be used. Slings alone shall not be used on a cylinder being transported or lifted. Also, cylinders should not be dropped, struck, or permitted to strike each other. 4.7.9 On arc welding machines, the control apparatus shall be enclosed except for the operating wheels, levers, or handles. 4.7.10 Input power terminals, top charge devices, and electrically energized metal parts shall be completely enclosed and accessible only by means of tools. 4.7.11 Terminals from welding leads shall be protected from accidental contact by personnel or metal objects. 4.7.12 The frame or case of an electrically driven arc welding machine shall be grounded. 4.7.13 Cables with splices within 10 ft (3.1 m) of the rod holder shall not be used. The welder should not coil or loop welding electrode cables around parts of his body.

7

5 Contractor Safety and Training When selecting contractors, operators should obtain and evaluate information regarding a contractorÕs safety policies and practices, and performance thereunder, and the contractorÕs procedures for selecting subcontractors. See API RP 2220. Contractors shall train their personnel in the work practices necessary to perform their jobs in a safe manner. The training provided to contract personnel should include applicable sitespeciÞc safety procedures and rules pertaining to the facility and the applicable provisions of emergency action plans. This section applies to contractors performing operating duties, maintenance or repair, turnaround, major renovation, or specialty work at the facility. Except for transportation safety orientation, emergency evacuation training, and other applicable safety training, this paragraph does not apply to contractors providing incidental services that do not inßuence operation of the facility, such as, janitorial work, food and drink services, laundry, delivery, other supply services, etc. The operator should verify contractor training utilizing a variety of methods, which may include audits of the contractorÕs safety training programs; worksite checks of individual contractor employeesÕ training; and operator observation of contractor work performance. A major step in achieving acceptable contractor performance is selecting a safe contractor. Therefore, it is appropriate for operators to request that contractors submit speciÞc performance information in their contract response proposals. For example, such information might include: a. Assurance of a contractorÕs written safety policies and practices endorsed by the contractor's top management. b. A statement of commitment by the contractor to comply with all applicable safety regulations and provisions of this publication. c. Recordable injury and illness experience for the previous 3 years. d. Experience ModiÞcation Rates (EMR) for WorkerÕs Compensation Insurance for the previous three years. e. An outline of the contractor's initial employee safety orientation. f. Evidence of the existence of a disciplinary action procedure dealing with safety and environmental related infractions. g. Descriptions of the contractorÕs various safety programs, including: accident investigation procedures; how safety inspections are performed; safety meetings; safety incentive programs; substance abuse prevention programs. h. Description of the safety and environmental training that each contractor employee has received and the contractor's programs for refresher training.

8

API RECOMMENDED PRACTICE 74

6 Safe Work Practices 6.1 LOAD LIFTING The manufacturerÕs rated load capacity shall not be exceeded on cranes or other load lifting devices. This equipment should be operated and maintained in accordance with manufacturersÕ recommendations. Tag lines should be used to guide and steady all loads being lifted. 6.2 CONFINED SPACE, EXCAVATIONS, AND HAZARDOUS ENVIRONMENTS 6.2.1 Where hydrogen sulÞde, sulfur dioxide, carbon dioxide or other hazardous atmosphere is known or suspected to exist, the operator shall ensure that personnel, contractor, and service company supervisors are advised of the potential hazards. Safety guidelines and recommendations for use in production operations where hydrogen sulÞde or sulfur dioxide gas may be encountered are contained in API RP 55. Also see ANSI 2117.1. 6.2.2 A conÞned space is an area which: a. Has adequate size and conÞguration for people to enter. b. Has limited means of entry or exit. c. Is not designed for continuous employee occupancy. 6.2.3 Examples of conÞned spaces that can be found at onshore producing facilities are: a. b. c. d. e. f. g.

Well cellars Electrical vaults Fin fan coolers Tanks Vessels Some diked areas Valve pits

6.2.4 ConÞned space hazards should be identiÞed for all facilities in the workplace and safe work practices should be established for working in the conÞned spaces. 6.2.5 A conÞned space entry permit shall be used to enter any conÞned space that has atmospheric, engulfment or conÞguration hazards. Attendant and emergency rescue service shall be provided for all permit required conÞned spaces. 6.2.6 When preparing the conÞned space for entry, precautions must be in place to ensure the space remains safe. This may include forced air ventilation, equipment isolation or other measures. For equipment isolation, consideration should be given to blinding, double block and bleed, or other equipment and energy isolation controls. 6.2.7 Trenching and Excavations When operations require excavating and preparing trenches, persons should be knowledgeable regarding the

hazards and precautions necessary for preparing and working in trenches. 1. Underground Hazards When preparing an excavation, consider the hazards of underground installations. These include electrical equipment, oil and gas transmission, sewers, water lines, telephone lines and other utilities. 2. Toxic Gas and Low Oxygen Hazards Any trench 4 ft or greater in depth is usually considered a ÒconÞned spaceÓ. Entry into these spaces is controlled by special safety procedures where oxygen deÞcient or toxic gas hazards can reasonably be expected, such as near landÞlls or near where hazardous materials are used or stored. There is concern that heavy gases can collect inside a trench. 3. Vehicle TrafÞc and Falling Loads Vehicles on nearby roadways and construction equipment can present hazards at an excavated site. Ensure that barricades and warnings are in place. Construction equipment shall not lift material over people in the trench or excavation. The soil from the trench is also a hazard to personnel inside the trench, for this reason it must be piled at least 2 ft from the edge of the trench. 4. Stability of Nearby Structures Before beginning an excavation it is important that consideration be given to nearby buildings, light poles or other structures in the area. Additional support, installed by professionals, may be needed. 5. Escape Means from Trenches A stairway, ladder or ramp should be located in any trench that is at least 4 ft (1.2m) deep. The escape means should be placed so that a person is never more that 25 ft away from an escape means. 6. Inspections A qualiÞed person should inspect the trench at least daily and more frequently if needed, such as after a rainstorm or other hazardous occurrence. 7. Prevention of Cave-Ins Any trench 5 ft or deeper, that is not in entirely stable rock, must be sloped or shored in accordance with recognized engineering practices. 6.3 LOCKOUT/TAGOUT 6.3.1 A lockout/tagout program shall be established to control hazardous energy as follows: a. Locks and/or tags should be placed to plainly identify the equipment or circuits being worked on. Systems locked or tagged should include the identity or job title of person installing the lock or tag. b. Personnel should be trained and disciplined in the use of this system to prevent unexpected operation of any equipment

RECOMMENDED PRACTICE FOR OCCUPATIONAL SAFETY FOR ONSHORE OIL AND GAS PRODUCTION OPERATIONS

that stores any type of energy that might inßict injury to personnel. c. The lock or tag should be removed by the person who installed it. In the event the individual is not available, the lock or tag may be removed by the supervisor after ensuring that no hazard will be created by energizing the locked or tagged equipment or circuit(s). Note: See NFPA 70.

6.3.2 Well Pumping Units 6.3.2.1 Power to the pumping unit should be deenergized and locked or tagged out to eliminate potential hazards during well servicing operations. In conÞned locations, overhead electric power to the pumping unit control panel should be deenergized. Where necessary, power service should be deenergized while moving the rig in or out and during rig-up and rig-down operations. See Lockout/Tagout. 6.3.2.2 During well servicing operations, the pumping unit shall be secured to prevent unintended movement. Use of the brake only or the brake and brake pawl are not acceptable means of securing the pump unit 6.3.2.3 Chain or wire rope sling of suitable strength should be used to handle the horsehead if removal or installation operations are necessary. On installation, the horsehead should be bolted or latched in accordance with the manufacturerÕs speciÞcations.

9

tem should consist of authorization to do the work along with the following: a. Pre-Work Stage Communications meetings addressing the following: 1. Simultaneous operations. 2. Air/gas testing. 3. Equipment isolation. 4. Equipment preparation. 5. IdentiÞcation of hazards. 6. Emergency procedures. b. Work-in-Progress Stage: 1. Posting of permit. 2. Air/gas testing. 3. Personal protective equipment requirements. 4. Fire watch. 5. Special procedures/precautions. c. Return to Service Stage: 1. Authorization and turnover signatures 6.4.1.2 The supervisor should hold a pre-job meeting with the crew and other involved persons to review responsibilities for the operation to be performed. 6.4.1.3 Welding and ßame cutting operations shall not be permitted close to ßammable liquids, accumulations of crude oil, escaping gas, or locations where sparks, ßames, heat, or hot slag could be sources of ignition. 6.4.1.4 Only qualiÞed persons should perform welding or ßame cutting operations on equipment used to contain hydrocarbons or hazardous materials.

6.3.2.4 Upon completion of well servicing operations and before energizing the power source, precautions shall be taken to ensure that all personnel and equipment are clear of the weight and beam movement.

6.4.1.5 Appropriate personal protective equipment shall be utilized for hot work operations.

6.3.2.5 Brake systems on all pumping units in service should be maintained in safe working order.

6.4.2.1 If the object to be cut or welded cannot readily be moved, all movable Þre hazards in the vicinity shall be taken to a safe place.

6.3.2.6 After well servicing operations are completed all pumping unit guards and enclosure guards (belt and motor sheaves) should be reinstalled prior to startup. Guards need not be in place until all Þnal adjustments (pump, spacing, etc.) are made, so long as the safety of personnel is not compromised.

6.4.2 Welding and Flame Cutting Operations

6.4.2.2 If the object to be welded or cut cannot be moved, and if all the Þre hazards cannot be removed, guards shall be used to conÞne the heat, sparks, and slag and to protect the immovable Þre hazards.

6.4.1 General

6.4.2.3 A safe welding area may be designated. In this area, welding and ßame cutting operations can be conducted with minimal concern of providing an ignition source for ßammable hydrocarbons or combustible materials. A safety work permit is not normally required for welding operations in an approved safe welding area.

6.4.1.1 A written safe work permit (hot work permit) system covering welding and ßame cutting operations should be observed. See NFPA 51B. In general, a safe work permit sys-

6.4.2.4 Properly maintained Þre extinguishing equipment shall be available for immediate use. A minimum of at least one 30-lb dry chemical Þre extinguisher shall be immediately

6.4 HOTWORK, WELDING, AND FLAME CUTTING OPERATIONS

10

API RECOMMENDED PRACTICE 74

available during welding or cutting operations. This equipment is in addition to the general Þre protection equipment. 6.4.2.5 Fire watches with extinguishing equipment shall be required whenever welding or cutting is performed in locations other than designated safe welding areas. 6.4.2.6 A Þre watch shall be maintained for at least onehalf hour after completion of welding or cutting operations. 6.4.2.7 Before cutting or welding is permitted in areas outside a designated safe welding area, the area shall be inspected by the individual responsible for authorizing cutting or welding operations. This individual shall designate the precautions to be followed in granting authorization to proceed. 6.4.2.8 Cutting or welding shall not be permitted in the following situations: a. In areas not authorized by the supervisor. b. In the presence of an explosive atmosphere. c. In areas near storage of large quantities of exposed readily-ignitable materials. d. Where ignition can be caused by heat conduction, such as on metal walls or pipes in contact with combustibles on the other side. e. On used containers such as drums unless properly cleaned. 6.4.2.9 Welding Fumes and Ventilation 6.4.2.9.1 Toxicity depends on the composition and concentration of the fumes. The composition and quantity of fumes depends on the materials being welded, the composition of the welding rods, any coatings or paints encountered in the welding operations, the process used, and the circumstances of use. Toxic fumes can be generated from welding on metals coated with or containing alloys of lead, zinc, cadmium, beryllium, and certain other metals. Some paints and cleaning compounds may also produce toxic fumes when heated. The potential health effects range in type and severity, depending on these factors; and some effects can be extremely serious. 6.4.2.9.2 For more information on the toxicity and health hazards of welding fumes and the appropriate protective measures, consult the following references: Industrial Ventilation, A Manual of Recommended Practice, 22nd Edition; Threshold Limit Values and Biological Indices for 1997-98; and API Publication 2201.

6.4.2.9.3 Mechanical ventilation at the minimum rate of 2,000 ft3/min (0.944 m3/s) per welder shall be provided when welding: a. In conÞned spaces or where the welding space contains partitions, balconies, or other structural barriers to the extent that they signiÞcantly obstruct cross ventilation. b. Where the nature of the welding, cutting, or brazing work is such that the release of toxic fumes or gases is possible. This includes work on stainless steel, zinc, lead, and degreasing or cleaning compounds containing hydrocarbons. 6.4.2.9.4 Adherence to conÞned space entry procedures shall be followed prior to any re-entries. For example, releases from acetylene cutting equipment could change the atmosphere within the conÞned space. 6.5 WORK IN PROXIMITY TO EXPOSED ENERGIZED POWER SOURCES 6.5.1 Neither equipment nor machines on rigs (includes guylines) shall be operated closer to power lines than the recommended minimum clearances shown in Table 2, except when such lines have been deenergized and visibly grounded or when barriers are present to prevent physical contact with the lines. 6.5.2 An individual should be designated to observe equipment clearance as deÞned in Table 2. The operator should notify the observer if he is having any difÞculty in determining the clearance. The observer should sound a warning at any time the clearance is not maintained. 6.5.3 When cage-type boom guards, insulating guylines, insulating links, or proximity warning devices on rigs or guylines are used, the recommendations of Table 2 are applicable. 6.5.4 Overhead wires should be considered energized (live) unless either the electrical system owner reports them to be non-energized, or a qualiÞed electrical person tests and Þnds them to be non-energized. Table 2—Recommended Minimum Clearances Between Power Lines and Derricks, Masts, or Guylines Equipment Operating

Line Voltage, Volts All

In transit (lowered mast)

less than or equal to 50 kV greater than 50 kV

Minimum Clearance 10 ft plus 4 in. for each additional 10 kV over 50 kV 4 ft 4 ft plus 4 in. for every additional 10 kV

RECOMMENDED PRACTICE FOR OCCUPATIONAL SAFETY FOR ONSHORE OIL AND GAS PRODUCTION OPERATIONS

7 Design 7.1 EMERGENCY EYE OR BODY WASH STATIONS Where the eyes or body of personnel may be exposed to injurious materials, eyewash and shower equipment for emergency use shall be provided. For information on emergency eyewash and shower equipment, see ANSI Z358.1. 7.2 CRITICAL EQUIPMENT Critical equipment is deÞned as equipment and other systems determined to be essential in preventing the occurrence of, or mitigating the consequences of an uncontrolled event. Such equipment may include pressure vessels, pressure relief devices, compressors, alarms, interlocks, and emergency shutdown systems.

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be conspicuously posted with a sign, ÒNO SMOKING OR OPEN FLAME,Ó or equivalent. 7.4.3 Smoking shall be permitted only in areas designated for smoking. 7.4.4 Change rooms and other buildings where smoking is permitted should be located in areas designated safe for smoking. 7.4.5 No source of ignition should be permitted in an area where smoking has been prohibited, unless it is Þrst determined safe to do so by the supervisor in charge or his designated representative. 7.4.6 Potential sources of ignition should be permitted only in designated areas located at a safe distance from the wellhead or ßammable liquid storage areas.

7.2.1 Critical equipment should be periodically inspected and tested as recommended by the manufacturer or in accordance with recognized engineering practices.

7.4.7 Equipment, cellars, ground areas around and adjacent to the facility should be kept free from oil and gas accumulations that might create or aggravate Þre hazards.

7.2.2 When using nondestructive testing (NDT) methods, qualiÞed persons should conduct the tests in accordance with recognized methodology and acceptance criteria. CertiÞed NDT inspectors shall be trained per ASNT RP No. ASNT-TC-1A.

7.4.8 Combustible materials such as oily rags and waste should be stored in covered metal containers and the covers kept in place.

7.2.3 Other types of inspection should be conducted by qualiÞed persons. 7.2.4 When critical equipment is removed from service, a program should be in place to ensure equivalent protection is provided. 7.3 CHANGES TO CRITICAL EQUIPMENT Procedures to manage changes (except for Òreplacements in kindÓ) to critical equipment should be implemented, as appropriate. These procedures should address the following prior to making the change: 1. The basis for the proposed change. 2. Impact of change on safety and health. 3. ModiÞcations to operating procedures. 4. Authorization requirements for the proposed change. Employees whose job tasks will be affected by the change in the critical equipment should be informed of the change prior to start-up. 7.4 FIRE PREVENTION 7.4.1 Safe storage and location of combustible and ßammable materials and the prevention of accumulation of rubbish are important to Þre prevention. 7.4.2 Smoking shall be prohibited at or in the vicinity of operations that constitute a Þre hazard. Such locations should

7.4.9 Natural gas or liqueÞed petroleum gas shall not be used to operate spray guns or pneumatic tools. 7.4.10 Material used for cleaning should have a ßash point of not less than 100¡F. 7.5 FIRE PROTECTION 7.5.1 Fire Þghting equipment shall not be tampered with and shall not be removed for other than Þre protection, Þre Þghting purposes, and services. A Þre Þghting water system may be used for wash down and other utility purposes so long as its Þre Þghting capability is not compromised. 7.5.2 Fire extinguishers and other Þre Þghting equipment should be suitably located, readily accessible, and plainly labeled as to their type and method of operation. 7.5.3 Fire suppression equipment (extinguishers, Þxed systems, etc.) should be periodically inspected and maintained in operating condition at all times. A record of the most recent equipment inspection should be maintained. 7.5.4 Portable Þre extinguishers shall be tagged with a durable tag showing the date of the last inspection, maintenance, or recharge or accomplished using other acceptable recordkeeping media. Inspection and maintenance procedures should comply with NFPA 10. 7.5.5 Personnel should be familiar with the location of Þre control and selected personnel trained in the use of such equipment. Fire Þghting equipment shall be accessible and free of obstructions.

12

API RECOMMENDED PRACTICE 74

7.6 GROUNDING AND BONDING Production facilities are subject to various forms of electrical hazards that must be protected against. Static electricity can be generated by ßuid movement in vessels, piping and tankage. This results in static sparks being generated which can be an ignition source. Lightning strikes to a facility are also an ignition source. Electrical equipment failure can occur exposing personnel to shock hazards. For guidelines to address these potential risks, refer to industry recommended practices such as API RP 2003 Protection Against Ignition Arising Out of Static, Lightning, and Stray Currents and NFPA 77 Static Electricity. 7.7 FLAMMABLE LIQUIDS 7.7.1 Containers 7.7.1.1 Hand portable containers for storing ßammable liquids should be Underwriters Laboratories (UL) listed or Factory Mutual (FM) approved, or equivalent.

Petroleum Gases, and NFPA 55 Compressed and LiqueÞed Gases in Portable Cylinders. 7.7.3.2 Ignition Source Control. Ignition source controls shall be established in any area where ßammable or oxidizing compressed gases are stored or used. 7.7.3.3 Protective Caps. Where compressed gas cylinders are designed to accept valve protective caps, the user should keep such caps on compressed gas cylinders at all times except when being Þlled or connected for use. 7.7.3.4 Where gas-tight valve outlet caps or plugs are provided, the user should keep such devices on the valve outlet at all times except when compressed gas cylinders are being Þlled or connected for use. 7.7.3.5 Compressed or liqueÞed gas cylinders in use or in storage shall be secured to prevent them from falling or being knocked over. 7.7.3.6 Compressed gas cylinders should be transported, stored and used in an upright position.

7.7.1.2 Tanks, drums, and other containers containing ßammable liquids should be properly labeled to denote their contents and should be properly stored when not in use.

7.7.3.7 Compressed gas cylinders exposed to Þre shall not be used until they are requaliÞed in accordance with the pressure vessel code under which they were manufactured.

7.7.1.3 Metal or other conductive material containers should be used in handling, storing, or transporting ßammable liquids. The handling of ßammable liquids in plastic containers is potentially dangerous due to static charge buildup. Metal parts on any plastic containers used in such service shall be bonded to the Þll connection. If plastic containers are used, the conductive Þll connection or a grounded rod should be inserted prior to Þlling the container with any ßammable liquid. See NFPA 77 and API RP 2003.

7.7.3.8 Containers that show denting, bulging, gouging, or excessive corrosion should be removed from service.

7.7.2 Fuel and Oil Transfers and Refueling 7.7.2.1 Hydrocarbon-fueled engines should be shut down during refueling operations. 7.7.2.2 Fuel tanks should be monitored while they are being Þlled to prevent overÞll and spillage. 7.7.2.3 During refueling operations, the Þlling nozzle should be kept in contact with the intake pipe to ensure bonding and prevent fuel spillage. 7.7.3 Liquified Petroleum Gas (LPG) and Compressed Gas 7.7.3.1 Handling, connecting, and transfer operations involving liqueÞed petroleum gas (LPG) shall conform to NFPA 58 Standard for the Storage and Handling of LiqueÞed

7.7.3.9 Repair or alteration of containers shall comply with the regulations, rules, or code under which the container was fabricated. 7.7.3.10 Compressed gas cylinders should be marked or labeled in accordance with CGA C-7 Guide to the Preparation of Precautionary Labeling and Marking of Compressed Gas Containers. Such markings or labels should not be removed. 7.7.3.11 Compressed gas cylinders shall not be placed where they could become a part of an electrical circuit. 7.7.3.12 Compressed gas cylinders should not be exposed to temperatures exceeding 125¡F. Cylinders shall not be subjected to direct heating to increase vapor pressure. 7.7.3.13 Stoves and heaters used with LPG fuel should only be used in well-ventilated areas. Personnel should ensure proper ventilation exists before lighting the heater/ stove. All hoses and connections on LPG stove or heater systems should be checked frequently to ensure they do not leak. 7.7.3.13.1 Only qualiÞed personnel should be allowed to Þll LPG bottles. Protective gloves should be worn when reÞlling or replacing LPG bottles. There is a possibility of freeze burns if propane comes in contact with skin.

RECOMMENDED PRACTICE FOR OCCUPATIONAL SAFETY FOR ONSHORE OIL AND GAS PRODUCTION OPERATIONS

7.7.4 Storage

7.8.2 Electrical Systems

7.7.4.1 Flammable liquids storage areas within any building or shed should:

7.8.2.1 Electrical Systems Equipment

a. Be adequately vented. b. Have unobstructed exit(s) leading from the building. c. Be maintained with due regard to Þre potential with respect to housekeeping and materials storage. d. Be identiÞed as a hazard and have appropriate warning signs posted. e. Have a Class BC Þre extinguisher (see NFPA 10) readily available. f. Be properly classiÞed for electrical installations in accordance with API RP 500 or API RP 505. 7.7.4.2 Paint and solvents should be stored in an adequately vented area safely away from heat and ignition sources.

13

7.8.2.1.1 Electrical equipment used in hazardous locations should be designed for such locations, and listed or approved by a nationally recognized testing laboratory. All wiring components and electrical equipment should be maintained in accordance with the manufacturerÕs recommendation. 7.8.2.1.2 Wiring should be replaced or properly repaired and sealed as necessary when insulation damage is detected. Because of Þre and other hazards, makeshift wiring components and installations should not be used. 7.8.3 Classification of Areas 7.8.3.1 ClassiÞcation of areas shall be in accordance with API RP 500 and RP 505.

7.7.4.3 Flammable liquids should not be stored within 50 ft (15.2 m) of the wellbore, except for fuel in the tanks of operating equipment. Where terrain and location conÞguration do not permit maintaining this distance, equivalent safety measures should be taken.

7.8.4 Tanks, Separators and Heater Treaters

7.8 EQUIPMENT

7.8.4.2 Walking directly on the roof of a tank is discouraged. However, if personnel are required to access the roof of a tank, roof integrity shall be checked and appropriate walking surfaces, guardrails or fall protection shall be provided.

7.8.1 Generators, Motors, and Lighting 7.8.1.1 All electrical conductors and switch gear shall be sized in accordance with NFPA 70. 7.8.1.2 All generators should have an overload safety device that will provide protection from shorting and burnout. 7.8.1.3 When adequate Þxed illumination cannot be made available, temporary portable lights approved for the electrical classiÞcation should be provided. Where possible, ßoodlights in use should be placed in positions so as not to impair vision of persons in the work area. Operations should not be performed using vehicle headlights as a substitute for lighting. 7.8.1.4 All electrical extension cords shall be properly insulated and plugs and receptacles shall be in good condition. 7.8.1.5 Light Þxtures should be placed and maintained to provide illumination for work areas in conformance with NECA/IESNA-502-99 Installing Industrial Lighting Systems ANSI Approved. 7.8.1.6 Repairs to electrical equipment shall not be performed unless the power source has been isolated and the control has been locked out/tagged out, and the person making the repairs is authorized to do so. 7.8.1.7 Electric motors, generators, and control panels shall be grounded.

7.8.4.1 Tanks, separators and heater treaters should be installed and maintained in accordance with accepted engineering practices or manufacturers recommendations. See API RP12R1, Specs 12J, 12K, 12L, 12P and RP12N.

7.8.5 Vapor Recovery Systems (Systems Designed to Minimize Vapor Releases to the Environment) 7.8.5.1 This section describes the safety guidelines for vapor recovery systems, specially thermal combustion systems and carbon absorption systems. See NFPA 30 for additional information. 7.8.5.2 Vapor recovery systems should be considered potential sources of ignition; facility design shall consider system location with respect to potential sources of hydrocarbon vapors. 7.8.5.3 Procedures should be developed for switching carbon beds and changing out the activated carbon in the absorbers. 7.8.5.4 Devices should be installed to prevent a ßame from propagating from the vapor recovery unit into the production equipment. See API RP12N.

8 Training 8.1 GENERAL All personnel should be trained to work safely in accordance with their duties and responsibilities. Personnel should

14

API RECOMMENDED PRACTICE 74

understand the safety and health hazards associated with the chemicals and processes they work with. Contractor personnel performing operating duties, maintenance or repair, turnaround, major renovation or specialty work should be knowledgeable of site-speciÞc safety procedures and rules pertaining to the facility and the applicable provisions of emergency action plans. Persons assigned to operate the facility or maintain the integrity of the equipment should possess the required knowledge and skills to carry out their duties and responsibilities and should be evaluated periodically to determine if the necessary skills and knowledge are adequate. Any major change that requires modiÞcation of existing operating practices may require additional training before personnel are expected to operate or maintain the facility.

9 Procedures 9.1 WELL STARTUP 9.1.1 General Introducing a new or worked-over well to a separation process, pipeline or storage facility may create additional hazards to the operation. The properties of the well should be reviewed to determine the extent of the hazards. Depending upon the risks of the hazards the following elements should be considered. 9.1.2 Design Review 9.1.2.1 A design review should be performed to verify that the facilityÕs equipment can safely process the wellstream. 9.1.2.2 The design information should include, as appropriate, a simpliÞed process ßow diagram and acceptable upper and lower limits, where applicable, for items such as temperature, pressure, ßow and hydrocarbon composition. Where process ßow diagrams no longer exist, similar information may be developed in conjunction with a hazards analysis in sufÞcient detail to support the analysis. 9.1.3 Pressure Relief Pressure relief systems should be properly sized, installed, maintained and operated to minimize overpressure. See API 520 and 521. 9.1.4 Startup Procedures 9.1.4.1 General Oil and gas wells have varying characteristics as follows: ÐShallow vs deep ÐLow vs high pressure

ÐSweet vs sour Startup procedures should be tailored to the particular well characteristics. Well startups are classiÞed as initial startup, normal or routine startups, and startup after an extended shutdown. 9.1.4.2 Pre Startup Safety Review Prior to startup of a new facility, or after modiÞcation of an existing facility, certain activities should be conducted to prepare the facility for safe operations. The following areas should be considered: 1. Construction has been completed according to design requirements. 2. Piping and valves are properly installed. 3. All safety and control devices are set and operate properly. 4. Applicable safety and control devices are functioning properly. 5. Eliminate potential ignition sources. 6. Pre-job safety meeting. 9.1.4.3 Initial Startup The following procedures should be considered: 1. Pressure test from well to choke at maximum wellhead pressure. 2. Pressure test from choke to production equipment, including ßowlines, at expected line pressure. 3. Pressure relief systems are operable. 4. Valves are set correctly. 5. Purge air from the well and associated equipment using hydrocarbons or other acceptable means. 6. Monitor ßow and bring well online. 7. Pre-job safety meeting. 9.1.4.4 Normal or Routine Startup The following procedures should be considered: 1. Pressure relief systems are operable. 2. Valves are set correctly. 3. Monitor ßow and bring well online. 4. Pre-job safety meeting. 9.1.4.5 Startup After Extended Shutdown After an extended shutdown, an equipment assessment should be conducted prior to well startup. This assessment should include inspections for corrosion, missing or modiÞed equipment, and overall integrity of the facility. After the assessment is competed, and repairs and corrections are made, well startup should follow initial startup procedures or normal startup procedures, as applicable.

RECOMMENDED PRACTICE FOR OCCUPATIONAL SAFETY FOR ONSHORE OIL AND GAS PRODUCTION OPERATIONS

9.1.5 Training of Employee and Contractor Personnel Personnel conducting well startup operations should be properly trained, qualiÞed, and familiar with well startup procedures for the speciÞc facility.

10 Maintenance

15

12.2 MEDICAL SERVICES 12.2.1 Telephone numbers, location, and other relevant information pertaining to availability of medical personnel, transportation, and medical facilities shall be available. 12.2.2 Provisions should be made for medical attention in case of injury.

10.1 GENERAL

12.3 FIRST AID

The maintenance supervisor should hold a pre-job meeting with his crew, and others if applicable, to review responsibilities for the operation(s) to be performed.

12.3.1 An individual trained in Þrst aid and cardiopulmonary resuscitation (CPR) techniques should be available to render aid. This individual should be trained using approved courses of the American Red Cross, American Heart Association, or equivalent training.

10.2 TANK CLEANING Tank cleaning should be completed following API Standard 2015, Safe Entry and Cleaning of Petroleum Storage Tanks. API Recommended Practice 2016, Entering and Cleaning Petroleum Storage Tanks should also be consulted for recommendations, guidance, safe practices and additional information covering speciÞc aspects of tank entry and cleaning, including a comprehensive tank cleaning checklist. 10.3 DRILLING AND WELL SERVICING Drilling and well servicing should be performed in accordance with API RP54.

11 Incident Investigation All incidents with the potential for serious safety consequences should be investigated to determine causal factors and steps taken to prevent a recurrence. The results of the investigation should be communicated to affected personnel including contractors as appropriate.

12 Emergency Response

12.3.2 A Þrst aid kit shall be available at the worksite. The kit should contain appropriate materials for the potential injuries, and should be inspected at frequent intervals, replenished as necessary, and be immediately available at all times.

13 Special Operations 13.1 WELL TESTING A cleanup tank should be used instead of a workover pit during well testing. Testing of casing relief valves using ßuids other than fresh water should have the relief piped to a catch tank. When pressure testing surface equipment, use a 50/50 mixture of glycol and 2% potassium chloride (KCl) water or equivalent to prevent ice formation. During well testing, the equipment should be pressure tested to maximum expected formation pressure. The following equipment should be included during the pressure testing: ¥ Test tree and casing for 10 minutes and record. ¥ Secure and pressure test lines upstream of choke prior to ßowback. ¥ Test lubricator. ¥ Test surface lines.

12.1 GENERAL Written action plans should be established for production facilities to assign authority to the appropriate qualiÞed person(s) for initiating effective emergency response and control. These plans should also address emergency reporting and response requirements. 12.1.1 Every occupational injury or illness shall be immediately reported to the supervisor. The supervisor shall arrange for any necessary medical or Þrst aid treatment. 12.1.2 A report should be prepared as soon as practical, to record information (or the circumstances) surrounding the injury or illness. Additional reports to regulatory agencies and others may be required.

13.2 PUMPING AND HOT OIL OPERATIONS (FLOWLINES) 13.2.1 All trucks and tanks should be located a minimum of 100 ft (30.5 m) upwind from the wellhead, or equivalent safety measures should be taken where terrain, location, or other conditions do not permit. At locations where this recommendation may be impractical, appropriate safety measures should be implemented. 13.2.2 All lines connected from the pumping equipment to the Christmas tree or wellhead should have a check valve installed as close to the well as practicable. In addition, when a multi-pump manifold is used, a check valve should be placed in each discharge line as close to the manifold as possible.

16

API RECOMMENDED PRACTICE 74

13.2.3 When used, recording equipment should be located a safe distance from the wellhead and discharge line. When pumping ßammable ßuids, all blending equipment used should be grounded and all equipment unloading sand into the hopper should be bonded to the blending equipment. When pumping ßammable ßuids, all charged suction hoses should be covered with hose covers to deßect ßuids in case of rupture. Lines containing ßammable ßuids should not be placed under any vehicle. A pre-treatment pressure test on the pump and discharge lines should be made at a pressure no less than the maximum expected treating pressure speciÞed by the operator, but not to exceed the rated working pressure of the equipment with the lowest rated working pressure. Personnel not directly involved in the operations should remain beyond a designated minimum distance during all pressure testing and pumping operations. The supervisor or the person he designates should check to see that all valves in discharge lines are open prior to pumping. Pump operators should remain at the controls while the pump is in operation, unless relieved as directed by the special services supervisor. Pump operators should remain alert for communications from the special services supervisor. 13.3 PIGGING OPERATIONS 13.3.1 Procedures should be developed for launching and receiving pigs, scrapers, swabs, and internal inspection pigs (smart pigs). These procedures should address the following elements: ¥ Description of the process ßuids and vapors, personnel hazards, and PPE. ¥ Selecting and verifying the proper pig is available. ¥ Preparing the pig launcher/receiver, including isolation, depressuring, and setting pig indicators. ¥ Verifying that the vessel is not pressurized. CAUTION: Gauges alone may not insure that the vessel is fully depressurized. Intentionally opening a pig launcher/receiver under pressure using any style of opener is prohibited. ¥ Opening the pig launcher/receiver CAUTION: Ensure all personnel are positioned at the side of the pig launcher/receiver. Do not stand in front of the pig launcher/receiver closure when the closure is being opened.

¥ Inserting and removing pigs, including isolation of ignition sources, containment of liquid wastes and exposure to toxic compounds. ¥ Inspecting and repairing as necessary pig launcher/ receiver closures, valves, pressure gauges, pig indicators, and other ancillary components each time the closure is opened. ¥ Closure of the pig launcher/receiver and returning it to service. ¥ Procedures to take in event the pig is stuck or any of the valves do not operate properly. 13.3.2 Only qualiÞed persons in pig launching/receiving should perform pigging operations. 13.3.3 A pre-job safety review should be preformed prior to all pig launching/receiving operations. Pig launchers/ receivers shall be depressurized whenever left isolated from the pipeline. 13.3.4 Fire extinguishing equipment should be positioned near the pig launcher/receiver when pigging operations are being performed. 13.4 HOT TAPPING ON EQUIPMENT IN SERVICE 13.4.1 Hot tapping operations should be conducted in accordance with API Publ 2201 Welding or Hot Tapping on Equipment in Service. 13.4.2 Hot tapping operations should be under the direct supervision of a qualiÞed person. The rated working pressure of all equipment used in hot tapping operations should be equal to or greater than the rated working pressure of the equipment to which it is being attached. 13.4.3 After necessary equipment has been rigged up to perform hot tapping operations, it should be pressure tested for a minimum of three minutes to a level not exceeding the rated working pressure of either the equipment being tapped or the tapping equipment and not to exceed 1.5 times the expected maximum pressure. The possibility of carrier or untapped pipe collapse from external pressure may dictate a reduction in test pressure. 13.4.4 During the hot tapping operation, pressure inside the lubricator should not exceed the pressure inside the equipment penetrated. 13.4.5 Hot taps or other hot work are not permitted on the roof of a tank or within the gas vapor space of the tank.

APPENDIX A—EXAMPLE LEASE PRODUCTION SAFETY CHECKLIST Date: _____________ Location: ____________________________ Codes:

Ö — Satisfactory

Inspected By:______________________________

X — Unsatisfactory *

NA — Not Applicable

ALARMS/SHUTDOWN _____Are alarms and shutdown systems operable & tested quarterly? _____Are level switches and dump valves operating properly? ELECTRICAL _____Is the wiring in good repair and unexposed? _____Are junction and switch box covers in place? _____Are electrical motors grounded? _____Is the conduit in good condition and all wiring in conduit? _____Are all electrical control panels labeled as to function and voltage? _____Is overhead powerline clearance a concern? FACILITY SIGNS _____Is a “Hard Hat Required” sign present? _____Is there a “NO SMOKING” sign at the entrance? _____If required, are there “Danger Poison Gas, H2S May Be Present” signs (> 10 ppm)? “Respiratory Protection Required” signs (> 100 ppm) and “Standby Required Beyond This Point” signs (> 300 ppm)? _____Are there “Unit Starts Automatically” warning signs? _____Are all process vessels, storage tanks and drums properly labeled (i.e., HAZCOM, NORM, ASBESTOS)? _____Are Lighting instructions posted on fired vessels (i.e., heater treaters, dehydrators, etc.)? _____Is there a “No Trespassing” or “Authorized Employees Only” sign at the entrance? _____Is the tank battery properly identified with a sign? _____Is there a lease sign at the location? _____If required, is there a Regulated Confined Space sign? FIRE EXTINGUISHERS _____Are all fire extinguishers inspected within the last 30 days? _____Are fire extinguishers fully charged, sealed and tagged? _____Have dry chemical cartridge operated fire extinguishers been hydrostatically tested according to schedule? GAS DETECTION INSTRUMENTS _____Are fixed and portable monitoring instruments calibrated and in good working condition? GUARDS _____Are all sight glasses guarded and in good condition? _____Do all pumps have the couplings and shafts guarded? _____Are all belts and pulleys totally enclosed? _____Are fans, flywheels and other moving parts properly guarded? _____Is live electrical/transformer equipment guarded? _____Is there a horse head guard on the pumping unit when below 7 ft? HAZARD COMMUNICATION STANDARD _____Are approved MSDSs provided for all appropriate products?

17

18

API RECOMMENDED PRACTICE 74

HOUSEKEEPING _____Have stumbling, tripping and falling hazards been eliminated or marked? _____Are all buildings in good repair? _____Have weeds been cut around the production equipment? _____Is the cattleguard properly maintained? LADDERS _____Are ladder rungs, rails, brackets, etc., in good condition? _____Are all ladders caged when over 20 ft? _____Do side rails of through or side-step ladders extend at least 31/2 ft above landings? _____Is the access opening to ladders provided with a swinging gate or chain closure? PRODUCTION EQUIPMENT _____Are all pressure gauges in good working order? _____Are all wellhead master and wing valves in good condition? _____Are valves and connections properly bolted, supported, and in good condition? _____Are aluminum, copper tubing and rubber hose not being used for hydrocarbon service? _____Is all process equipment properly anchored for movement from wind and vibration? _____Are burner flame arrestors in good condition? PUMPING UNIT _____Are there guard rails around the unit? _____Is there proper spacing between the guard rails and the counter weights (min-15"/max-42")? _____Does the brake function properly? _____Is the throat bolt present and tight (if required by the manufacturer)? _____Is there 4" clearance between the polish rod yoke and top of stuffing box at bottom of stroke? RELIEF VALVES _____Are relief valve inspections current? _____Are block valves which affect the operation of relief valves, sealed or locked in the open position? _____Are relief valves discharged up and away from personnel and equipment? _____Are relief valves set at or under the maximum allowable working pressure of the protected equipment? _____Are all pressure vessels protected with relief valves? _____Rupture disk(s) visually examined for leakage? RESPIRATORY EQUIPMENT (If provided) _____Are all respirators sanitized and properly stored? _____Have all emergency use respirators been inspected and documented within the last 30 days? ROADWAYS _____Are there any roadway hazards that need to be marked, guarded or eliminated? (anchors, pipelines, risers, etc.) TANKS, VESSELS _____Are walkways and stairways in good order? _____Are there toeboards on elevated walkways over 4 ft? _____Do the tank thief hatches seal and are they in good repair? _____Are process vessels and storage tanks in sound condition with no sign of corrosion problems? _____Is the insulating or protective coating material in good condition? _____Are vessel/tank foundations in good repair and free of washout or undercutting? _____Does the tank have a vent line attached and is it free of obstruction? _____Are all pressure vessels operating at or below their maximum allowable working pressure? _____Has the insulation been analyzed and labeled if it contains asbestos? _____Are tanks examined visually to check for leaks, tank distortion, corrosion, coating and cathodic protection conditions?

RECOMMENDED PRACTICE FOR OCCUPATIONAL SAFETY FOR ONSHORE OIL AND GAS PRODUCTION OPERATIONS

PIPING _____Are all valves and connections in good operating condition? _____Are the facility piping systems in sound condition, with no sign of leaks or potential corrosion problems? REMARKS: ____________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ Note: Requires clarification (specify items and locations)

19

APPENDIX B—EXAMPLE COMPRESSOR/BOOSTER STATIONS SAFETY CHECKLIST Work Group: _________________________

Date: ____________________________________

Location: ____________________________

Inspected By:_____________________________

Codes:

Ö — Satisfactory

X — Unsatisfactory *

NA — Not Applicable

ALARMS/SHUTDOWN _____Are alarms and shutdown systems tested quarterly? _____Are tests documented and records maintained. GAS DETECTION INSTRUMENTS _____Are fixed monitoring instruments (i.e., hydrogen sulfide, hydrocarbon) calibrated and in good working condition? ELECTRICAL _____Are electrical tools and cords in good operating condition? _____Where appropriate, is explosion proof lighting and equipment provided and used? _____Are electrical cords properly insulated and/or provided with ground? _____Are all electrical installations in good condition and installed according to regulations (any exposed wiring)? _____Are ground fault circuit interrupters (GFCIs) utilized? _____Are PCB containing systems labeled and documented? _____Are all electrical control panels labeled as to function and voltage? _____Are junction and switch box covers in place? _____Are electrical motors properly grounded? EMERGENCY RESPONSE _____Is an emergency response plan provided? _____Are drills conducted and documented? _____Are emergency phone numbers provided and updated? _____Is the facility properly identified and an emergency number provided? EQUIPMENT _____Are all sight glasses guarded? _____Are pump couplings, belts, gears, chain drives, shafts, pulleys and flywheels properly guarded? _____Are high temperature systems insulated or equipped with guards for personnel protection where needed? _____Is engine/piping vibration at a minimum? Are vibration shutdowns effective? _____Are all vessels and equipment properly grounded? _____Are the ignition system components free from broken insulation, cracks or grease? _____Are all pressure gauges in good working order? _____Are all lights working and do they provide adequate illumination? _____Is the concrete in good structural condition? _____Is the compressor's exhaust system free of leaks? _____Are gas starters leak free and properly vented? _____Are skids equipped with migrant oil containment systems? _____Are pressurized drains separate from non-pressurized drains? _____Are there water traps on drains? _____Are start-up and shutdown procedures posted? _____Is manual starting valve on the opposite side of the starter and is fuel regulator vented to cooler? _____Are compressor rod distance pieces vented away from unit? _____Are there any underground storage tanks at this location?

21

22

API RECOMMENDED PRACTICE 74

FACILITY SIGNS _____Is a “Hard Hat Required” sign present? _____Is there a “NO SMOKING” sign, as appropriate? _____Are there “Danger Poison Gas, H2S May Be Present” signs (> 100 ppm), “Respiratory Protection Required” signs (> 10 ppm), and “Standby Required Beyond This Point” signs (> 300 ppm), if required? _____Are there “Danger, This Unit Starts Automatically” warning signs, if required? _____Are “Hearing Protection Required” signs present where noise level exceeds 85 dBA? _____Are lighting instructions posted on fired vessels (i.e., heater treaters)? _____Is there a “No Trespassing, Authorized Employees Only” sign at the principle entrance? _____Is there a “Regulated Confined Space” sign? _____If a NORM notification sign is required, is it posted? FIRE EXTINGUISHERS _____Are all fire extinguishers inspected within the last month? _____Are fire extinguishers fully charged and tagged? _____Have cartridge operated fire extinguishers been hydrostatically tested within the past 12 years? _____Are records maintained on each fire extinguisher? HAZARD COMMUNICATION STANDARD _____Are MSDSs provided for all appropriate products? _____Are all process vessels, storage tanks and drums properly labeled (i.e., HAZCOM, NORM)? _____Has lead paint use been eliminated? _____Has lead paint been identified/labeled? HOUSEKEEPING _____Have stumbling, tripping, and falling hazards been eliminated or marked? _____Are all buildings in good repair? _____Have weeds been cut around the location? _____Is the road at the facility in good condition? LADDERS _____Are fixed ladders caged when over 20 ft? _____Are portable ladders in good condition? _____Are scaffolds in good condition? _____Do through or side-step ladders extensions extend at least 3.5 ft above landings? _____Are ladder rungs, rails, brackets, etc., in good condition? MATERIAL HANDLING _____Are aisles and passageways accessible for entering and exiting? _____Are all hoists properly labeled and in good condition? _____Is preventive maintenance up to date? _____Are cranes inspected monthly and in good condition? _____Are slings, ropes and chains inspected regularly and in good condition with appropriate recordkeeping? _____Are load tests on file? PIPING _____Are all valves and connections in good operating condition? _____Are the facility piping systems in good condition, with no sign of leaks or potential corrosion problems? _____Are cathodic protection rectifier readings current (per the manufacturer's recommendations)? _____Is the cathodic protection system inspected annually? _____Are open-ended valves plugged?

RECOMMENDED PRACTICE FOR OCCUPATIONAL SAFETY FOR ONSHORE OIL AND GAS PRODUCTION OPERATIONS

RELIEF VALVES _____Are relief valve inspections current? _____Are rupture disks visually examined for leakage? _____Are test records and tags available? _____Are block valves upstream of the relief valves sealed or locked in the open position? _____Are relief valves discharged up and away from personnel and equipment? _____Are relief valves set at or under the maximum allowable working pressure of the protected equipment? RESPIRATORY PROTECTION _____Are respirators appropriate for exposure being worn? _____Are all respirators sanitized and properly stored? _____Have all emergency use respirators been inspected within the last 30 days? (Records maintained?) _____Is the air supply for respirators sufficient? PPE _____Is eye protection provided and used? _____Is appropriate footwear being worn? _____Are hard hats being worn? _____Is hearing protection available and being worn? TANKS, VESSELS _____Are walkways and stairways in good order? _____Are there toeboards on elevated walkways? _____Are process vessels and storage tanks in sound condition with no sign of potential corrosion problems? _____Is the insulation or protective coating material in good condition? _____Has the insulation been analyzed for asbestos content? _____Do tank thief hatches seal and are they in good repair?

REMARKS: ____________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________

23

Effective January 1, 2007. API Members receive a 30% discount where applicable. The member discount does not apply to purchases made for the purpose of resale or for incorporation into commercial products, training courses, workshops, or other commercial enterprises.

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Spec 6A, Wellhead and Christmas Tree Equipment

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Spec 11E, Pumping Units RP 11ER, Guarding of Pumping Units (ANSI)

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Mail Orders – Payment by check or money order in U.S. dollars is required except for established accounts. State and local taxes, $10 processing fee, and 5% shipping must be added. Send mail orders to: API Publications, IHS, 15 Inverness Way East, c/o Retail Sales, Englewood, CO 80112-5776, USA. Purchase Orders – Purchase orders are accepted from established accounts. Invoice will include actual freight cost, a $10 processing fee, plus state and local taxes. Telephone Orders – If ordering by telephone, a $10 processing fee and actual freight costs will be added to the order. Sales Tax – All U.S. purchases must include applicable state and local sales tax. Customers claiming tax-exempt status must provide IHS with a copy of their exemption certificate. Shipping (U.S. Orders) – Orders shipped within the U.S. are sent via traceable means. Most orders are shipped the same day. Subscription updates are sent by First-Class Mail. Other options, including next-day service, air service, and fax transmission are available at additional cost. Call 1-800-854-7179 for more information. Shipping (International Orders) – Standard international shipping is by air express courier service. Subscription updates are sent by World Mail. Normal delivery is 3-4 days from shipping date. Rush Shipping Fee – Next Day Delivery orders charge is $20 in addition to the carrier charges. Next Day Delivery orders must be placed by 2:00 p.m. MST to ensure overnight delivery. Returns – All returns must be pre-approved by calling the IHS Customer Service Department at 1-800-624-3974 for information and assistance. There may be a 15% restocking fee. Special order items, electronic documents, and age-dated materials are non-returnable.

Effective January 1, 2007. API Members receive a 30% discount where applicable. The member discount does not apply to purchases made for the purpose of resale or for incorporation into commercial products, training courses, workshops, or other commercial enterprises.

Available through IHS:

2007 Publications Order Form Quantity

Phone Orders: Fax Orders: Online Orders:

1-800-854-7179 (Toll-free in the U.S. and Canada) 303-397-7956 (Local and International) 303-397-2740 www.global.ihs.com

★ To be placed on Standing Order for future editions of this publication, place a check mark in the SO column and sign where indicated on the other side of this form. Pricing and availability subject to change without notice.

Product Number

Title

G04902

RP 49, Drilling and Well Servicing Operations Involving Hydrogen Sulfide

$78.00

G54003

RP 54, Occupational Safety for Oil and Gas Well Drilling and Servicing Operations

$111.00

G55002

RP 55, Oil and Gas Production and Gas Processing Plant Operations Involving Hydrogen Sulfide

$101.00

G07503

RP 75, Recommended Practice for Development of a Safety and Environmental Management Program for Outer Continental Shelf (OCS) Operations and Facilities

$81.00

C50002

RP 500, Classification of Locations for Electrical Installations at Petroleum Facilities Classified as Class I, Zone 0, Zone 1, and Zone 2

$181.00

C50501

RP 505, Classification of Locations for Electrical Installations at Petroleum Facilities Classified as Class I, Zone 0, Zone 1, and Zone 2

$181.00

C51009

Publ 510, Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair, and Alteration

$134.00

SO★

Unit Price

Publ 520, Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries

$153.00

C52105

Publ 521, Guide for Pressure-Relieving and Depressuring Systems

$195.00

K75202

RP 752, Management of Hazards Associated with Location of Process Plant Buildings, CMA Managers Guide

$86.00

D110420

Std 1104, Welding of Pipelines and Related Facilities

$263.00

K20036

RP 2003, Protection Against Ignitions Arising Out of Static, Lightning, and Stray Currents

$111.00

K20097

Publ 2009, Safe Welding and Cutting Practices in Refineries, Gasoline Plants, and Petrochemical Plants

$69.00

K20156

Std 2015, Safe Entry and Cleaning Petroleum Storage Tanks

$120.00

K22015

Publ 2201, Procedures for Welding or Hot Tapping on Equipment in Service

$76.00

K22075

Publ 2207, Preparing Tank Bottoms for Hot Work

$58.00

K2217A3

Publ 2217A, Guidelines for Work in Inert Confined Spaces in the Petroleum Industry

$66.00

K222002

RP 2220, Improving Owner and Contractor Safety Performance

$73.00

K22212

RP 2221, Managers Guide to Implementing a Contractor Safety Program

$135.00

C25108

Publ 2510, Design and Construction of Liquefied Petroleum Gas (LPG) Installations

$92.00

K2510A

Publ 2510A, Fire-Protection Considerations for the Design and Operation of Liquefied Petroleum Gas (LPG) Storage Facilities

$90.00

R9100S

Publ 9100, Model Environmental Health and Safety Management System and Guidance Document

$140.00

C52017

Subtotal (Transfer to other side of Order Form)

Total

10/01

Additional copies are available through Global Engineering Documents at (800) 854-7179 or (303) 397-7956 Information about API Publications, Programs and Services is available on the World Wide Web at: http://www.api.org

Product No. G74001